Uni-Tool for Foldable Transportable Structure Deployment

ABSTRACT

A tool for the deployment of a foldable transportable structure comprising an elongate housing, an elongate threaded worm screw rotatably mounted to the elongate housing, a slider block defining both a threaded slider passage into which is threaded the worm screw and a slider pin aperture for receiving a slider unfolding pin, and means for constraining the slider block from rotating upon rotation of the worm screw, such that the slider block translates along the length of the worm screw upon rotation thereof. A first end of the elongate housing defines a housing pin aperture for receiving a housing unfolding pin. There is also provided means for applying torque to the worm screw to rotate the worm screw and cause the displacement of the slider block along the length of the worm screw relative to the housing

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 63/344,116, which was filed on May 20, 2022. The entire content of the foregoing provisional application is incorporated herein by reference.

FIELD OF THE INVENTION

The inventions herein relate to structures, such as dwellings and other buildings for residential occupancy, commercial occupancy and/or material storage, and to components for such structures.

BACKGROUND Description of the Related Art

In the field of residential housing, the traditional technique for building homes is referred to as “stick-built” construction, where a builder constructs housing at the intended location using in substantial part raw materials such as wooden boards, plywood panels, and steel columns. The materials are assembled piece by piece over a previously prepared portion of ground, for example, a poured concrete slab or a poured concrete or cinder block foundation.

There have been a variety of efforts to depart from the conventional construction techniques used to create dwellings, as well as commercial spaces and like, in an effort to reduce costs. In this regard, a significant advancement is embodied in the Boxabl® foldable transportable dwelling unit, which consists of a number of enclosure components (four wall components, a floor component and a roof component), and portions thereof, which are dimensioned, positioned and folded together to form a compact shipping module 15, as shown in FIG. 1A. The enclosure components and enclosure component portions are dimensioned so that the shipping module 15 is within applicable highway dimensional restrictions. As a result, shipping module 15 can be transported over a limited access highway more easily, and with appropriate trailering equipment, transported without the need for oversize load permits. Thus, the basic components of structure 150 can be manufactured in a factory, positioned and joined together to form the shipping module 15, and the modules 15 can then be transported to the desired site for the structure, where they can be readily deployed (unfolded) to yield a relatively finished structure 150, which is shown in FIG. 1B.

The process of unfolding the enclosure component and component portions of shipping module 15 is often conducted with a mobile crane. Dispensing with the use of such a crane in many cases is desirable, both to simplify the deployment process as well as to facilitate deployment in situations where a mobile crane may not be readily available.

SUMMARY OF THE INVENTION

The present invention constitutes an advancement in means for deploying a foldable transportable structure.

In a first aspect, the present invention is directed to a tool for the deployment of a foldable transportable structure comprising an elongate housing, an elongate threaded worm screw rotatably mounted to the elongate housing, a slider block defining both a threaded slider passage into which is threaded the worm screw and a slider pin aperture for receiving a slider unfolding pin, and means for constraining the slider block from rotating upon rotation of the worm screw, such that the slider block translates along the length of the worm screw upon rotation thereof. A first end of the elongate housing defines a housing pin aperture for receiving a housing unfolding pin. There is also provided means for applying torque to the worm screw to rotate the worm screw and cause the displacement of the slider block along the length of the worm screw relative to the housing.

In some embodiments, the elongated housing can be a C-shaped channel. The tool can include a first guide rail and a second guide rail secured to inner sides of the elongated housing. The tool can include an end cap coupled to a first end of the elongated housing. The tool can include a first bearing disposed within an opening of the end cap and configured to receive a first end of the threaded worm screw. The tool can include a collar secured to the end cap to limit axial movement of the threaded worm screw and the first bearing. The tool can include a removable end cap cover configured to cover the first bearing and the collar. The tool can include a motor end cap fitted to a second end of the elongated housing. The tool can include a second bearing disposed within the motor end cap and configured to receive a second end of the threaded worm screw. The tool can include a removable motor end cap closure plate configured to limit axial movement of the threaded worm screw and the second bearing. The slider block can define a T-shaped configuration including a body and co-planar slider wings extending from opposing ends of the body. The threaded slider passage extends through the slider block in a direction perpendicular to the slider pin aperture. The tool can include a scissor assembly including two elongate bars each including a first end and a second end. The first end of each of the two elongate bars is hingedly joined together to the slider unfolding pin. The slider unfolding pin hingedly joins the first end of the two elongate bars to the slider block. The second end of each of the two elongate bars includes a bar end pin.

In a second aspect, the present invention is directed to a method of constructing a folded building structure, where the folded building structure includes a building unit, a first enclosure member and a second enclosure member. The building unit, the first enclosure member and the second enclosure member each has a pin support affixed thereto for receiving an unfolding pin, and the first and second enclosure members are each joined in a folded position to the building unit and moveable with respect thereto. The method employs a tool comprising an elongate housing, an elongate threaded worm screw rotatably mounted to the elongate housing, a slider block defining both a threaded slider passage into which is threaded the worm screw and a slider pin aperture for receiving a slider unfolding pin. The tool includes means for constraining the slider block from rotating upon rotation of the worm screw, such that the slider block translates along the length of the worm screw upon rotation thereof, and a first end of the elongate housing defines a housing pin aperture for receiving a housing unfolding pin. The method comprises inserting a first end of a first unfolding pin in the pin support affixed to either the building unit or the first enclosure member, inserting a first end of a second unfolding pin in the pin support affixed to the second enclosure member, inserting a second end of the first unfolding pin in a first of the slider pin aperture or the housing pin aperture, inserting a second end of the second unfolding pin in a second of the slider aperture or the housing pin aperture, and rotating the worm screw.

These and other aspects of the present inventions are described in the drawings annexed hereto, and in the description of the preferred embodiments and claims set forth below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a folded building structure (a shipping module), and

FIG. 1B is a perspective view of an unfolded building structure.

FIG. 2 is a top schematic view of the structure shown in FIG. 1B.

FIG. 3 is an end view of a shipping module as shown in FIG. 1A, from which is formed the structure shown in FIG. 1B.

FIGS. 4A and 4B respectively are perspective and perspective exploded views of the uni-tool of the present invention.

FIG. 5 is a section view depicting the top end cap region of the present invention.

FIG. 6 is a section view depicting the motor end cap region of the present invention.

FIG. 7 is a perspective view of the slider of the present invention.

FIG. 8A is a perspective view of a uni-tool of the present invention being used to deploy a floor portion of a shipping module, and FIG. 8B is a perspective view showing in more detail the joinder between the uni-tool and the floor portion.

FIG. 9A is a perspective view of a uni-tool/scissor assembly combination of the present invention being used to deploy roof portions of a shipping module, and FIG. 9B is a perspective view showing in more detail the joinder of the scissor assembly to the uni-tool.

FIGS. 10A, 10B, 10C and 10D are perspective views showing the sequence of unfolding of roof portions of a shipping module, using the uni-tool/scissor assembly combination of the present invention, to provide a fully deployed structure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

An embodiment of the foldable, transportable structure 150 in which the inventions disclosed herein can be implemented is depicted in FIGS. 1A-5 . When fully unfolded, as exemplified by FIG. 1B, structure 150 has a rectangular shape made of three types of generally planar and rectangular enclosure components 155, the three types of enclosure components 155 consisting of a wall component 200, a floor component 300, and a roof component 400. As shown in FIGS. 1A, 1B and 2 , the perimeter of structure 150 is defined by first longitudinal edge 106, first transverse edge 108, second longitudinal edge 116 and second transverse edge 110. For convenience, a direction parallel to first longitudinal edge 106 and second longitudinal edge 116 may be referred to as the “longitudinal” direction, a direction parallel to first transverse edge 108 and second transverse edge 110 may be referred to as the “transverse” direction; and a direction parallel to the vertical direction in FIGS. 1A and 1B may be referred to as the “vertical” direction. Structure 150 as shown has one floor component 300, one roof component 400 and four wall components 200; although it should be understood that the present inventions are applicable to structures having other configurations as well.

Enclosure Component (155): General Description

The enclosure components 155 of the present invention include a number of shared design features that are described below.

A. Laminate Structure Design

Enclosure components 155 can be fabricated using a multi-layered, laminate design. A particular laminate design that can be used to fabricate enclosure components 155 is described in U.S. Non-Provisional patent application Ser. No. 17/552,108, entitled “Enclosure Component Fabrication Facility,” filed on Dec. 15, 2021. The contents of that U.S. Non-Provisional patent application Ser. No. 17/552,108, entitled “Enclosure Component Fabrication Facility,” filed on Dec. 15, 2021, are incorporated by reference as if fully set forth herein, particularly including the multi-layered, laminate designs described for example at ¶¶0027-0032 and depicted in FIG. 7 .

Other embodiments of multi-layered, laminate designs that can be used to fabricate the enclosure components 155 of the present invention, are described in U.S. Non-Provisional patent application Ser. No. 16/786,130, entitled “Foldable Building Structures with Utility Channels and Laminate Enclosures,” filed on Feb. 10, 2020 and now issued as U.S. Pat. No. 11,118,344. The contents of that U.S. Non-Provisional patent application Ser. No. 16/786,130, entitled “Foldable Building Structures with Utility Channels and Laminate Enclosures” and filed on Feb. 10, 2020, are incorporated by reference as if fully set forth herein, particularly including the multi-layered, laminate designs described for example at ¶¶0034-57 and depicted in FIGS. 4A-4D thereof.

B. Enclosure Component Exterior Edge Reinforcement

The exterior edges of each enclosure component 155 (i.e., the edges that define the perimeter of enclosure component 155) can be provided with exterior edge reinforcement, as desired. Exterior edge reinforcement generally comprises an elongate, rigid member which can protect foam panel material that would otherwise be exposed at the exterior edges of enclosure components 155. Exterior edge reinforcement can be fabricated from one or more of laminated strand lumber board, wooden board, C-channel extruded aluminum or steel, or the like, and is generally secured to the exterior edges of enclosure component 155 with fasteners, such as screw or nail fasteners, and/or adhesive.

C. Enclosure Component Partitioning

Enclosure components 155 in certain instances are partitioned into enclosure component portions to facilitate forming a compact shipping module 15. In those instances where an enclosure component 155 is partitioned into enclosure component portions, any exterior edge reinforcement on the exterior edges defining the perimeter of the enclosure component is segmented as necessary between or among the portions.

The enclosure component portions can be joined by hinge structures or mechanisms to permit the enclosure component portions to be “folded” and thereby contribute to forming a compact shipping module 15.

D. Enclosure Component Interior Edge Reinforcement

An enclosure component 155 partitioned into enclosure component portions will have interior edges. There will be two adjacent interior edges for each adjacent pair of enclosure component portions. Such interior edges can be provided with interior edge reinforcement. Similar to exterior edge reinforcement, such interior edge reinforcement generally comprises an elongate, rigid member which can protect foam panel material that would otherwise be exposed at the interior edges of enclosure components 155. Interior edge reinforcement can be fabricated from one or more of laminated strand lumber board, wooden board, C-channel extruded aluminum or steel, or the like, and is generally secured to the interior edges of enclosure component 155 with fasteners, such as screw or nail fasteners, and/or adhesive.

Further design details of wall component 200, floor component 300, and roof component 400 are provided in the sections following.

Wall Component (200)

Typically, structure 150 will utilize four wall components 200, with each wall component 200 corresponding to an entire wall of structure 150.

A. General Description

Wall component 200 has a generally rectangular perimeter. As shown in FIG. 1B, wall components 200 have plural apertures, specifically a door aperture 202, which has a door frame and door assembly, and plural window apertures 204, each of which has a window frame and a window assembly. The height and length of wall components 200 can vary in accordance with design preference, subject as desired to the dimensional restrictions applicable to transport, described above. In this disclosure, structure 150 is fashioned with all sides of equal length; accordingly, its first and second longitudinal edges 106 and 116, and its first and second transverse edges 108 and 110, are all of equal length. It should be understood however, that the inventions described herein are applicable to structures having other dimensions, such as where two opposing wall components 200 are longer than the other two opposing wall components 200.

B. Partitioned Wall Components

Referring to FIG. 2 , structure 150 has two opposing wall components 200, where one of the two opposing wall components 200 comprises first wall portion 200 s-1 and second wall portion 200 s-2, and the other of the two opposing wall components 200 comprises third wall portion 200 s-3 and fourth wall portion 200 s-4. Each of wall portions 200 s-1, 200 s-2, 200 s-3 and 200 s-4 has a generally rectangular planar structure. As shown in FIG. 2 , the interior vertical edge 192-1 of wall portion 200 s-1 is proximate to a respective interior vertical edge 192-2 of wall portion 200 s-2, and the interior vertical edge 194-3 of wall portion 200 s-3 is proximate a respective interior vertical wall edge 194-4 of wall portion 200 s-4.

Referring again to FIG. 2 , first wall portion 200 s-1 is fixed in position on floor portion 300 a proximate to first transverse edge 108, and third wall portion 200 s-3 is fixed in position on floor portion 300 a, opposite first wall portion 200 s-1 and proximate to second transverse edge 110. First wall portion 200 s-1 is joined to second wall portion 200 s-2 with a hinge structure that permits wall portion 200 s-2 to pivot about vertical axis 192 between a folded position and an unfolded position, and third wall portion 200 s-3 is joined to fourth wall portion 200 s-4 with a hinge structure to permit fourth wall portion 200 s-4 to pivot about vertical axis 194 between a folded position and an unfolded position.

Notably, first wall portion 200 s-1 is longer than third wall portion 200 s-3 by a distance approximately equal to the thickness of wall component 200, and second wall portion 200 s-2 is shorter than fourth wall portion 200 s-4 by a distance approximately equal to the thickness of wall component 200. Furthermore, wall portion 200 s-1 and wall portion 200 s-3 are each shorter in length (the dimension in the transverse direction) than the dimension of floor portion 300 a in the transverse direction. Dimensioning the lengths of wall portions 200 s-1, 200 s-2, 200 s-3 and 200 s-4 in this manner permits wall portions 200 s-2 and 200 s-4 to nest against each other in an overlapping relationship when in an inwardly folded position. In this regard, FIG. 2 depicts wall portions 200 s-2 and 200 s-4 both in their unfolded positions, where they are labelled 200 s-2 u and 200 s 4-u respectively, and FIG. 2 also depicts wall portions 200 s-2 and 200 s-4 both in their inwardly folded positions, where they are labelled 200 s-2 f and 200 s 4-f respectively. When wall portions 200 s-2 and 200 s-4 are in their inwardly folded positions (200 s-2 f and 200 s-4 f), they facilitate forming a compact shipping module. When wall portion 200 s-2 is in its unfolded position (200 s-2 u), it forms with wall portion 200 s-1 a wall component 200 proximate first transverse edge 108, and when wall portion 200 s-4 is in its unfolded position (200 s-4 u), it forms with wall portion 200 s-3 a wall component 200 proximate second transverse edge 110.

C. Unpartitioned Wall Components

As compared to the two wall components 200 proximate first and second transverse edges 108 and 110, which are partitioned into wall portions, the remaining two wall components 200 proximate first and second longitudinal edges 106 and 116 do not comprise plural wall portions, but rather each is a single piece structure. However, one of these wall components 200, which is sometimes denominated 200P in this disclosure, and which is located on floor portion 300 b proximate first longitudinal edge 106, is pivotally secured to floor portion 300 b to permit wall component 200P to pivot about horizontal axis 105 shown in FIG. 3 from a folded position to an unfolded position. Pivotally securing wall component 200P also facilitates forming a compact shipping module 15. The remaining wall component 200, sometimes denominated 200R in this disclosure, is rigidly secured on floor portion 300 a proximate second longitudinal edge 116 and abutting the vertical edges of first wall portion 200 s-1 and third wall portion 200 s-3 proximate to second longitudinal edge 116, as shown in FIG. 2 .

Floor Component (300)

Typically, structure 150 will utilize one floor component 300; thus floor component 300 generally is the full floor of structure 150.

A. General Description

Floor component 300 has a generally rectangular perimeter. The length and width of floor component 300 can vary in accordance with design preference. In the particular embodiment of structure 150 depicted in FIGS. 1B and 2 , floor component 300 is approximately 19 feet (5.79 m) by 19 feet (5.79 m).

Floor component 300 and its constituent elements are generally designed and dimensioned in thickness and in other respects to accommodate the particular loads to which floor component 300 may be subject.

B. Floor Partitioning

The floor component 300 is partitioned into floor portion 300 a and floor portion 300 b. FIG. 2 shows flow portions 300 a and 300 b in plan view. Each of the floor portions 300 a and 300 b is a planar generally rectangular structure, with floor portion 300 a adjoining floor portion 300 b.

Referring to structure 150 shown in FIGS. 1B, 2 and 3 , floor portion 300 a is fixed in position relative to first wall portion 200 s-1, third wall portion 200 s-3 and wall component 200R. Floor portion 300 a is joined with hinge structures to floor portion 300 b, so as to permit floor portion 300 b to pivot through approximately ninety degrees (90°) of arc about a horizontal axis 305, generally located as indicated in FIG. 3 , proximate the top surface of floor component 300, between a fully folded position, where floor portion 300 b is vertically oriented as shown in FIG. 3 , and the fully unfolded position shown in FIG. 2 , where floor portion 300 b is horizontally oriented and co-planar with floor portion 300 a.

Roof Component (400)

Typically, structure 150 will utilize one roof component 400; thus roof component 400 generally is the full roof of structure 150.

A. General Description

Roof component 400 has a generally rectangular perimeter. FIG. 1B depicts roof component 400. The length and width of roof component 400 can vary in accordance with design preference. In the particular embodiment of structure 150 depicted in FIGS. 1A, 1B, 2 and 3 , the length and width of roof component 400 approximates the length and width of floor component 300.

Roof component 400 and its constituent elements are generally designed and dimensioned in thickness and in other respects to accommodate the particular loads to which roof component 400 may be subject.

B. Roof Partitioning

The roof component 400 of structure 150 is partitioned into roof portions 400 a, 400 b and 400 c, shown in FIGS. 1A and 3 when folded, and in FIG. 1B when unfolded. Each of the roof portions 400 a, 400 b and 400 c is a planar generally rectangular structure, with roof portion 400 a adjoining roof portion 400 b, and roof portion 400 b adjoining roof portion 400 c.

In the shipping module 15 shown in FIG. 3 , roof portions 400 a, 400 b and 400 c preferably are accordion folded (stacked), with roof component 400 b stacked on top of roof component 400 a, and roof component 400 c stacked on top of the roof component 400 b. As can be appreciated from FIG. 3 , roof portion 400 a is fixed in position relative to first wall portion 200 s-1, third wall portion 200 s-3 and wall component 200R. Thus to realize the accordion folded configuration shown in FIG. 3 roof portion 400 a is joined to roof portion 400 b with hinge structures that are adapted to permit roof portion 400 b to pivot through up to one hundred and eighty degrees (180°) of arc about a horizontal axis 405 a (see FIG. 3 ) between the roof fully folded position shown in FIGS. 1A and 3 , where roof portion 400 b lies stacked flat against roof portion 400 a, and the fully unfolded position shown in FIG. 1B. In turn, roof portion 400 b is joined to roof portion 400 c with hinge structures that are adapted to permit roof portion 400 c to pivot through up to one hundred and eighty degrees (180°) of arc about a horizontal axis 405 b (see FIG. 3 ) between the folded position shown in FIGS. 1A and 3 , where roof portion 400 c lies stacked flat against roof portion 400 b (when roof portion 400 b is positioned to lie flat against roof portion 400 a), and the fully unfolded position shown in FIG. 1B.

Fixed Space Portion Build-Out and Finishing

Referring to FIG. 2 , structure 150 includes a fixed space portion 102 defined by roof component 400 a (shown in FIG. 3 ), floor component 300 a, wall component 200R, wall portion 200 s-1 and wall portion 200 s-3. (Fixed space portion 102 is also shown edge-on in the shipping module 15 depicted in FIG. 3 ). It is preferred that the fixed space portion 102 be fitted out during manufacture with internal components, such as kitchens, bathrooms, closets, storage areas, corridors, etc., so as to be in a relatively finished state prior to shipment of shipping module 15. Also, in the embodiment shown in FIGS. 1A, 1B and 2 , wall components 200 are fitted during manufacture and prior to shipment with all necessary door and window assemblies, with the enclosure components 155 being pre-wired for electrical needs.

Carrying out the foregoing steps prior to shipment permits the builder, in effect, to erect a largely finished structure simply by “unfolding” (deploying) the positioned components of shipping module 15.

Enclosure Component Relationships and Assembly for Transport

It is preferred that there be a specific dimensional relationship among enclosure components 155.

FIG. 2 shows a top schematic view of structure 150 shown in FIG. 1B, and includes a geometrical orthogonal grid for clarity of explaining the preferred dimensional relationships among its enclosure components 155. The basic length used for dimensioning is indicated as “E” in FIG. 2 ; the orthogonal grid overlaid in FIG. 2 is 8E long and 8E wide; notably, the entire structure 150 preferably is bounded by this 8E by 8E orthogonal grid.

Roof portions 400 a, 400 b and 400 c each can be identically dimensioned in the transverse direction. Alternatively, referring to FIG. 3 , roof portion 400 c can be dimensioned to be larger than either of roof portion 400 a and roof portion 400 b in the transverse direction to reduce the chances of binding during the unfolding of roof portions 400 b, 400 c. Further specifics on dimensioning roof portion 400 c in the foregoing manner are described in U.S. Non-Provisional application Ser. No. 17/569,962, entitled “Improved Folding Roof Component,” filed on Jan. 6, 2022. In addition, as described in U.S. Non-Provisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” filed on Feb. 10, 2020 and now U.S. Pat. No. 11,220,816, as well as in U.S. Non-Provisional application Ser. No. 17/569,962 mentioned above, friction-reducing components can be used to facilitate unfolding roof component 400, such as by positioning a first wheel caster at the leading edge of roof portion 400 c proximate to the corner of roof portion 400 c that is supported by wall portion 200 s-2 as roof portion 400 c is deployed, and by positioning a second similar wheel caster at the leading edge of roof portion 400 c proximate to the corner of roof portion 400 c that is supported by wall portion 200 s-4 as roof portion 400 c is deployed.

In FIG. 2 , the four wall components 200 are each approximately 8E long, and each of roof portions 400 a and 400 b is approximately 8E long and 2.5E wide. Roof portion 400 c is approximately 8E long and 2.9E wide. In FIGS. 2 and 3 , each of floor components 300 a and 300 b is 8H long; whereas floor component 300 a is just over 3E wide and floor component 300 b is just under 5E wide.

As shown in FIG. 2 , fourth wall portion 200 s-4 is folded inward and positioned generally against fixed space portion 102, and second wall portion 200 s-2 is folded inward and positioned generally against fourth wall portion 200 s-4 (wall portions 200 s-2 and 200 s-4 are respectively identified in FIG. 2 as portions 200 s-2 f and 200 s-4 f when so folded and positioned). The three roof components 400 a, 400 b and 400 c are shown unfolded in FIG. 1B and shown folded (stacked) in FIG. 3 , with roof component 400 b stacked on top of roof component 400 a, and roof component 400 c stacked on top of the roof component 400 b. Wall component 200P, shown in FIGS. 2 and 3 , is pivotally secured to floor portion 300 b at the location of axis 105, and is vertically positioned against the outside of wall portions 200 s-2 and 200 s-4. In turn, floor portion 300 b is vertically positioned proximate fixed space portion 102, with wall component 200P pending from floor portion 300 b between floor portion 300 b and wall portions 200 s-2 and 200 s-4.

Sizing the enclosure components 155 of structure 150 according to the dimensional relationships disclosed above yields a compact shipping module 15, as can be seen from the figures. Thus shipping module 15 depicted in FIG. 3 , when dimensioned according to the relationships disclosed herein using an “E” dimension (see FIG. 2 ) of approximately 28.625 inches (72.7 cm), and when its components are stacked and positioned as shown in FIG. 3 , has an overall length of approximately 19 feet (5.79 m), an overall width of approximately 8.5 feet (2.59 meters) and an overall height of approximately 12.7 feet (3.87 meters). These overall dimensions are less than a typical shipping container.

Each of the wall, floor and roof components 200, 300 and 400, and/or the portions thereof, can be sheathed in protective film 177 during fabrication and prior to forming the shipping module 15. Alternatively or in addition, the entire shipping module 15 can be sheathed in a protective film. Such protective films can remain in place until after the shipping module 15 is at the construction site, and then removed as required to facilitate enclosure component deployment and finishing.

Shipping Module Transport

The shipping module 15 is shipped to the building site by appropriate transport means. One such transport means is disclosed in U.S. Non-Provisional application Ser. No. 16/143,628, filed Sep. 27, 2018 and now U.S. Pat. No. 11,007,921, issued May 18, 2021; the contents of that U.S. Non-Provisional application Ser. No. 16/143,628, filed Sep. 27, 2018, are incorporated by reference as if fully set forth herein, particularly as found at paragraphs 0020-0035 and in FIGS. 1A-2D thereof. As an alternative transport means, shipping module 15 can be shipped to the building site by means of a conventional truck trailer or a low bed trailer (also referred to as a lowboy trailer), and in the case of over-the-water shipments, by ship.

Structure Deployment and Finishing

At the building site, shipping module 15 is positioned over its desired location, such as over a prepared foundation; for example, a poured concrete slab, a poured concrete or cinder block foundation, sleeper beams or concrete posts or columns. This can be accomplished by using a crane, either to lift shipping module 15 from its transport and move it to the desired location, or by positioning the transport means over the desired location, lifting shipping module 15, then moving the transport means from the desired location, and then lowering shipping module 15 to a rest state at the desired location. Particularly suitable equipment and techniques for facilitating the positioning of a shipping module 15 at the desired location are disclosed in U.S. Non-Provisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” and filed on Feb. 10, 2020, now U.S. Pat. No. 11,220,816. The contents of that U.S. Non-Provisional patent application Ser. No. 16/786,315, entitled “Equipment and Methods for Erecting a Transportable Foldable Building Structure,” and filed on Feb. 10, 2020, are incorporated by reference as if fully set forth herein, particularly including the equipment and techniques described for example at ¶¶126-128 and in connection with FIGS. 11A and 11B thereof.

Following positioning of shipping module 15 at the building site, the appropriate portions of wall, floor and roof components 200, 300 and 400 are “unfolded” (i.e., deployed) to yield structure 150. Unfolding occurs in the following sequence: (1) floor portion 300 b is pivotally rotated about horizontal axis 305 (shown in FIG. 3 ) to an unfolded position, (2) wall component 200P is pivotally rotated about horizontal axis 105 (the general location of which is shown in FIG. 3 ) to an unfolded position, (3) wall portions 200 s-2 and 200 s-4 are pivotally rotated about vertical axes 192 and 194 (shown in FIG. 2 ) respectively to unfolded positions, and (4) roof portions 400 b and 400 c are pivotally rotated about horizontal axes 405 a and 405 b (shown in FIG. 3 ) respectively to unfolded positions.

Uni-Tool (500): Description and Use

Instead of using a mobile crane to assist in the deployment of certain sections of the enclosure components 155 (specifically roof portions 400 b and 400 c, floor portion 300 b, as well as the wall component 200P pivotally secured to floor portion 300 b), the uni-tool 500 of the present invention, depicted in FIGS. 4A-7 , can be utilized to deploy all of these enclosure component sections.

Referring to FIGS. 4A and 4B, uni-tool 500 includes an elongate C-Channel 501, two opposed guide rails 502, an elongate worm screw 503, a T-shaped slider 504 and two bearings 506. The guide rails 502 are secured to the inner sides of C-channel 501 in any suitable manner, such as with adhesives or fasteners. C-channel 501 can be fabricated from grade 6061 aluminum, and optionally, guide rails 502 can be integrally fabricated with C-channel 501 in lieu of being separately fabricated. Worm screw 503 is provided with exterior screw threads along its length. Worm screw 503 can be fabricated from grade 4140 alloy steel.

As shown in FIGS. 4A, 4B and 5 , a top end cap 505 is fitted to a first end of C-channel 501 and includes a first bearing 506-1 that receives a first end of worm screw 503. A collar 507 can be secured to cap 505 to assist in limiting axial movement of worm screw 503 and first bearing 506-1. A removable end cap cover 508 provides service access to first bearing 506-1 and collar 507. Referring now to FIG. 6 , a motor end cap 509 is fitted to a second end of C-channel 501 and includes a first interior region 523 to accommodate a second bearing 506-2 that receives a second end of worm screw 503. Motor end cap 508 further includes a second interior region 524 that is closed off by a removable motor end cap closure plate 512, which both assists in limiting axial movement of worm screw 503 and second bearing 506, and also provides service access to the first and second interior regions of motor end cap 509. The first and second bearings 506 permit worm screw 503 to be freely rotated while under axial loading. Suitable designs for bearings 506 include tapered roller bearings made of for example stainless steel. Motor end cap 509 is provided with a trunnion mount 517 for receiving a removable pin, as described further below.

Slider 504, shown in detail in FIG. 7 , in general has a T-shape, with the head of the “T” having two co-planar slider wings 515 extending from the body of the “T”. Slider wings 515 are received in C-channel 501 and constrained therein by guide rails 502 so as to be capable of sliding motion along the length of C-channel 501. There is also provided a circular worm screw passage 513 through C-channel 501 (located in general terms at the head of the “T”). The worm screw passage 513 is threaded to mate with worm screw 503 such that rotation of worm screw 503 causes slider 504 to move along the length of C-channel 501. The body of the “T” of slider 504 is provided with a pin aperture 514, oriented orthogonally to the geometrical plane defined by slider wings 515, for receiving a cylindrical pin 519.

Motor end cap 509 shown in FIG. 6 can contain such components as are desired to facilitate the application of a suitable torque to worm screw 503 and thereby cause rotation. The source of the torque can be manually applied, such as by personnel turning a hand crank connected to worm screw 503 through motor end cap 509, geared as may be appropriate, or can be applied by utilization of motive power, such as an electric motor energized by a conventional 12-volt battery power source. In the embodiment shown, motor end cap 509 includes a first pulley 510-1 joined to worm screw 503 at its second end, below second bearing 506-2, and further includes a second pulley 510-2 rotationally mounted within motor end cap 509. The first and second pulleys 510-1, 510-2 are rotationally coupled by a belt 511. To achieve a desired amount of torque, belt 511 can include teeth that engage corresponding teeth provided about the circumferences of pulleys 10. The shaft of an appropriate source of motive power, such as an electric motor, can be inserted into circular channel 516 of motor end cap 509 to engage second pulley 510-2 and rotate worm screw 503 when energized.

In use, uni-tool 500 is secured at times during deployment (unfolding) to a number of flange mounts 518 located on shipping module 15. More specifically, a first set of four flange mounts 518 is secured at each of the locations shown in FIGS. 8A and 8B, as follows: (a) a first flange mount 518-1 is secured to the first transverse edge 108 of roof portion 400 b, (b) a second flange mount 518-2 is secured to the first wall portion 200 s-1, (c) a third flange mount 518-3 is secured to the first transverse edge 108 of floor portion 300 b, and (d) a fourth flange mount 518-4 is secured to the first transverse edge 108 of wall component 200P. Likewise, one of a second set of four flange mounts 518 (not visible in the figures) is secured at comparable locations to: (a) a fifth flange mount 518-5 is secured to the second transverse edge 110 of roof portion 400 b, (b) a sixth flange mount 518-6 is secured to the third wall portion 200 s-3, (c) a seventh flange mount 518-7 is secured to the second transverse edge 110 of floor portion 300 b, and (d) an eighth flange mount 518-8 is secured to the second transverse edge 110 of wall component 200P. Thus in unfolding, two uni-tools can be used in accordance with preference. However, for purposes of simplicity, the unfolding operations are described below only with respect to one the more visible uni-tool 500 shown in the figures (proximate to first transverse edge 108, it being understood that the same sequence of steps can be carried out simultaneously using the second uni-tool 500 shown in the figures (proximate to second transverse edge 110).

Unfolding Step 1: Deploying Floor Portion 300 b.

A pin 519 is inserted into the pin channel of trunnion mount 517 of the uni-tool 500 and received in flange mount 518-3, as shown in FIG. 8B. In addition, a pin 519 is inserted into slider aperture 514 of the uni-tool 500 and received in flange mount 518-2 (see FIG. 8A), with worm screw 503 being rotated as necessary to position slider 504 proximate to flange mount 518-2. Worm screw 503 is then rotated in the appropriate direction to lower floor portion 300 b in a controlled manner to its fully deployed (unfolded) position, as shown in FIG. 8A.

Unfolding Step 2: Deploying Wall Component 200P.

The pin 519 in slider aperture 514 is disengaged from flange mount 518-2, and worm screw 503 is then rotated as necessary to position slider 504 proximate to flange mount 518-4. The pin 519 in slider aperture 514 is then inserted into flange mount 518-4. Worm screw 503 is then rotated in the appropriate direction to raise wall component 200P in a controlled manner to its fully deployed (unfolded) position.

Unfolding Step 3: Deploying Wall Portions 200 s-1, 200 s-3.

Wall portions 200 s-1 and 200 s-3 are vertically hinged and thus can be unfolded by hand.

Unfolding Step 4: Deploying Roof Portions 400 b, 300 c.

To deploy roof portions 400 b and 400 c, a scissor assembly 520 is utilized in conjunction with uni-tool 500. Referring to FIGS. 9A and 9B, scissor assembly 520 comprises two elongate bars 521, each having a first end and a second end. The first ends of elongate bars 521 are hingedly joined together to a pin 519, as shown in FIG. 9B, which is inserted into slider aperture 514 of slider 504. The second end of each elongate bar 521 is provided with a bar end pin 522. A first bar end pin 522 is inserted into flange mount 518-1 and a second bar end pin 522 is inserted into flange mount 518-2, with worm screw 503 being rotated to be proximate to top end cap 505 and to permit the bar end pins 522 to engage mounts 518-1 and 518-2. Once the uni-tool 500/scissor assembly 520 combination is so placed, worm screw 503 is rotated to draw slider 504 toward motor end cap 509. The kinematic relationship between the uni-tool 500/scissor assembly 520 combination and the relevant members of structure 150 urge the roof portions 400 b and 400 c to deploy (unfold) in a controlled manner to their fully unfolded positions, as sequentially illustrated in FIGS. 10A-10D.

After unfolding, the enclosure components 155 are secured together to finish the structure 150 that is shown in FIG. 1B. During or after unfolding and securing of the enclosure components 155, any remaining finishing operations are performed, such as addition of roofing material, and making hook-ups to electrical, fresh water and sewer lines to complete structure 150, as relevant here.

The foregoing detailed description is for illustration only and is not to be deemed as limiting the inventions disclosed herein, which are defined in the appended claims. 

What is claimed is:
 1. A tool for the deployment of a foldable transportable structure, comprising: an elongate housing; an elongate threaded worm screw rotatably mounted to the elongate housing; a slider block defining (i) a threaded slider passage into which is threaded the worm screw and (ii) a slider pin aperture for receiving a slider unfolding pin; means for constraining the slider block from rotating upon rotation of the worm screw, such that the slider block translates along the length of the worm screw upon rotation thereof; a first end of the elongate housing defining a housing pin aperture for receiving a housing unfolding pin; and means for applying torque to the worm screw to rotate the worm screw and cause the displacement of the slider block along the length of the worm screw relative to the housing.
 2. The tool according to claim 1, wherein the elongated housing is a C-shaped channel.
 3. The tool according to claim 1, comprising a first guide rail and a second guide rail secured to inner sides of the elongated housing.
 4. The tool according to claim 1, comprising an end cap coupled to a first end of the elongated housing.
 5. The tool according to claim 4, comprising a first bearing disposed within an opening of the end cap and configured to receive a first end of the threaded worm screw.
 6. The tool according to claim 5, comprising a collar secured to the end cap to limit axial movement of the threaded worm screw and the first bearing.
 7. The tool according to claim 6, comprising a removable end cap cover configured to cover the first bearing and the collar.
 8. The tool according to claim 5, comprising a motor end cap fitted to a second end of the elongated housing.
 9. The tool according to claim 8, comprising a second bearing disposed within the motor end cap and configured to receive a second end of the threaded worm screw.
 10. The tool according to claim 9, comprising a removable motor end cap closure plate configured to limit axial movement of the threaded worm screw and the second bearing.
 11. The tool according to claim 1, wherein the slider block defines a T-shaped configuration including a body and co-planar slider wings extending from opposing ends of the body.
 12. The tool according to claim 1, wherein the threaded slider passage extends through the slider block in a direction perpendicular to the slider pin aperture.
 13. The tool according to claim 1, comprising a scissor assembly including two elongate bars each including a first end and a second end.
 14. The tool according to claim 13, wherein the first end of each of the two elongate bars is hingedly joined together to the slider unfolding pin.
 15. The tool according to claim 13, wherein the slider unfolding pin hingedly joins the first end of the two elongate bars to the slider block.
 16. The tool according to claim 13, wherein the second end of each of the two elongate bars includes a bar end pin.
 17. A method of constructing a folded building structure, (A) the folded building structure including (i) a building unit, (ii) a first enclosure member and (iii) a second enclosure member, (iv) the building unit, the first enclosure member and the second enclosure member each having a pin support affixed thereto for receiving an unfolding pin, and (v) the first and second enclosure members each being joined in a folded position to the building unit and moveable with respect thereto, the method employing (B) a tool comprising an (i) elongate housing, (ii) an elongate threaded worm screw rotatably mounted to the elongate housing, (iii) a slider block defining a threaded slider passage into which is threaded the worm screw and a slider pin aperture for receiving a slider unfolding pin, (iv) means for constraining the slider block from rotating upon rotation of the worm screw, such that the slider block translates along the length of the worm screw upon rotation thereof, and (v) a first end of the elongate housing defining a housing pin aperture for receiving a housing unfolding pin, the method comprising: (a) inserting a first end of a first unfolding pin in the pin support affixed to either the building unit or the first enclosure member; (b) inserting a first end of a second unfolding pin in the pin support affixed to the second enclosure member; (c) inserting a second end of the first unfolding pin in a first of the slider pin aperture or the housing pin aperture; (d) inserting a second end of the second unfolding pin in a second of the slider aperture or the housing pin aperture; and (e) rotating the worm screw. 